I/O endforming tool for forming tubes and method of manufacture thereof

ABSTRACT

An I/O endforming tool for forming an end of a tube, the tool having a cone ring expandable and contractable conical I/O jaw assembly, a barrel assembly, a plurality of I/O fingers and mandrel assembly, wherein the I/O jaw assembly has a plurality of conical jaw segments, one segment adjacent two neighbouring segments, each segment having a recess within each of its sides adjacent each neighbouring segment and biasing member retained within each recess to effect a biasing effect between adjacent jaw segments the improvement wherein each recess formed at a portion of the outer circumference of each segment as to define a radial trough when the jaw assembly is in its expanded position; and the biasing member is a solid, non-metallic deformable member retained within a circumferential recess defined by a pair of adjacent the troughs when the jaw assembly is in its contracted position. The process of manufacture provides improved saving in time, handling, efficiency, consistency and quality. The deformable member is preferably formed of and provides for greater force, higher grease and fluid resistance and tolerance and rust resistance over metal coil springs presently in commercial use.

FIELD OF THE INVENTION

This invention relates to endforming tooling, particularly segmented I/O segmented jaws for forming the end of tubes for use, particularly, in automotive applications and to the manufacture thereof.

BACKGROUND OF THE INVENTION

I/O endforming tooling forms the end of tubing generally used in automotive applications and comprises inside and outside segmented forming parts, called fingers and jaws, contained in a barrel assembly. The I/O fingers are expanded by a tapered mandrel that stabs the tooling axially to expand the segments radially. The fingers, which are the inside tube forming segments, are returned to the start closed position by an elastomer band, which circumferentially wraps around the fingers at their non-tube forming base. The I/O jaws act in an opposite fashion and are collapsed by a cone ring moving axially along the segments to cause radial collapse onto the tube. Conventional prior art assemblies returns the jaws to the desired open position using coiled metal springs located between segments contained in individual pockets.

However, there is a need to provide an improved I/O jaws assembly having equal spacing between jaw segments and having a more uniform and higher initial force over the movement of the I/O jaws than conventional equipment, while significantly reducing manufacturing costs.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an improved I/O endforming tool for forming the ends of tubes.

It is a further object to provide a method of manufacture of said I/O endforming tool.

Accordingly, in one aspect the invention provides an I/O endforming tool for forming an end of a tube, said tool comprising a cone ring expandable and contractable conical I/O jaw means, a barrel assembly, a plurality of I/O fingers and mandrel means, wherein said I/O jaw means comprises a plurality of conical jaw segments, one segment adjacent two neighbouring segments, each segment having a recess within each of its sides adjacent each neighbouring segment and biasing means retained within each recess to effect a biasing effect between adjacent jaw segments the improvement wherein each recess formed at a portion of the outer circumference of each segment as to define a radial trough when said jaw means is in its expanded position; and said biasing means comprises a solid, non-metallic deformable member retained within a circumferential recess defined by a pair of adjacent said troughs when said jaw means is in it contracted position.

Preferably, the deformable member has a body in the shape of a right-vertical obligate cylinder having a pair of opposite vertical sides of greater length than the length of the pair of vertical adjacent sides. More, preferably, at least one of the vertical sides of greater length defines a vertical recess. More, preferably, each of the vertical sides of greater length of the body defines a recess to constitute the body having a waist.

Preferably, at least one of the troughs of each jaw segment defines has an inner trough radial recess and the deformable member has a protrusion partly receivable within the inner trough radial recess.

A most preferred deformable member is formed of a polyurethane.

Thus, in the form of a peanut-shaped member, the non-metallic material acts like a non-compressible liquid and when compression is attempted, deforms into the space provided by the shape of the body and the open-ended pocket it sits in.

The present invention provides the following improvements and advantages over the prior art.

It offers an extended life span over the prior art coiled metal spring, while giving a “price against performance” advantage.

Since the deformable biasing member is non-magnetic, it does not attract metal chips, which can reduce the performance of the prior art metal springs.

The member provides a more uniform and higher initial spring rate, which is important when the I/O jaws want to continue grabbing the tube after it has been formed into them. i.e. in deep groove/dimpling applications

The solid deformable member will not break or score the jaw segment surfaces.

In a further aspect, the invention provides a means of effecting the addition of the plurality of deformable members to their respective recesses of adjacent fingers in the assembly of the jaw assembly, wherein the plurality of deformable members are integrally formed at and around the inner circumferential surface of a band, said band being of a suitable diameter as to allow the members to be fitted around the jaw assembly when it is in its expanded, assembled mode. The band arrangement facilitates entry and retention within the recesses of the members, simultaneously. The band is of a suitable thickness as to not interfere with the contraction and expansion of the jaw assembly in operation.

Conventional prior art manufacturing methods require 2 drilled flat bottom holes for each segment made, whereas the recess for the solid member of the present invention results from a single drilled hole for each pair of segments subsequently made, with an alignment notch provided at point of I/O jaw turning, which provides considerable savings in time and handling over conventional turn, saw, and spring pocket operations.

Accordingly, in a further aspect the invention provides a method of manufacturing an expandable and contractable I/O jaw means comprising a plurality of conical jaw segments, wherein each segment is adjacent two neighbouring segments at their radially adjacent sides for use in an I/O endforming tool assembly, said method comprising providing an integrally-formed, open-ended, hollow conical member having a body and a radially upstanding circumferential flange adjacent the end of greater outside diameter of said body the improvement comprising

(a) drilling a plurality of radial cylindrical recesses within and symmetrically aligned around said flange;

(b) slicing said member through said body and said flange through said recesses to provide said plurality of jaw segments, wherein each segment has a portion defining a radial trough at the outer circumference of said segment at each of said radially adjacent sides; which troughs define a plurality of deformable member-receiving cylindrical recesses within and when said I/O jaw assembly is in the contracted position;

(c) inserting said deformable members between and within adjacent troughs prior to said I/O jaws being contracted.

Preferably, in a further aspect the invention provides a method as hereinabove defined further comprising the step of drilling at least one notch-receiving recess within each of said radial, cylindrical recesses prior to step (b)

The improved process accuracy increases consistency and, therefore, of I/O tooling quality.

The non-metallic member has advantages over the prior art helical coil metal springs in providing greater force, higher grease and fluid resistance and tolerance, and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be better understood, preferred embodiments will now be described, by way of example only, with reference to the accompanying drawings wherein FIG. 1 is an exploded, perspective view of an I/O endforming tool assembly, according to the prior art;

FIG. 2 is a front sectional view of a barrel assembly with assembled fingers and jaws, according to the prior art;

FIG. 3 is a side sectional view of a barrel assembly with assembled fingers and jaws, along the line B-B′ of FIG. 2, according to the prior art;

FIG. 4 is an exploded, side-sectional view of a jaw assembly (in part) of the tool assembly of FIG. 1;

FIG. 5 is a sectional view along the line A-A′ of FIG. 4;

FIG. 6 is an exploded side-sectional view of a jaw assembly (in part), according to the invention;

FIG. 7 is a sectional view along the line C-C′ of FIG. 6;

FIG. 8 is a side-sectional view of a contracted jaw assembly, according to the invention; and FIG. 8A is an enlarged view of part of FIG. 8;

FIG. 8B is a sectional view along the line D-D′ of FIG. 8;

FIG. 9 is a side sectional view of an expanded jaw assembly, according to the invention; and FIG. 9A is an enlarged view of part of FIG. 9;

FIG. 10 is a diagrammatic perspective view of a deformable member in an expanded mode of use in the jaw assembly, according to the invention;

FIG. 10A is an end view of the member of FIG. 10, viewed along the sight line “S”;

FIG. 11 is a diagrammatic view of a deformable member in its contracted mode;

FIG. 12 is a perspective view of a jaw assembly, according to the invention, showing arrangement of the deformable members as they would be within and between adjacent jaw segments;

FIG. 13 is a perspective view of a jaw segment and associated helical spring, according to the prior art;

FIG. 14 is a perspective view of a jaw segment and associated deformable member, according to the invention;

FIG. 15 is a diagrammatic perspective view of a band of deformable members of use in the practise of the invention;

FIG. 15A is a diagrammatic axial sectional view of the band of FIG. 15;

FIG. 15B is a side, radial view of the band of FIG. 15; and wherein the same numerals denotes like parts.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIG. 1 shows generally as 10, a prior art I/O endforming tool assembly for forming the end of a tube 12. The tool assembly 10 can be used to expand or contract the tube at its end.

Assembly 10 in its basic form has a cone ring 14 which receives tube 12, and which reduces jaw assembly 16 within barrel assembly 18, which has a lifting handle 20 and a back plate 22. An I/O finger assembly 24 comprises a plurality of fingers 26 and a flange 28, which abuts backplate 22, within barrel assembly 18. A stabbing member or mandrel 30 has a lifting handle 32 and is part of a mandrel assembly (not shown).

FIGS. 2 and 3 are views of barrel assembly 18 having a barrel 34 surrounding jaw assembly 16, which in turn embraces fingers 36 of finger assembly 24.

FIGS. 4 and 5 are exploded views of jaw assembly 16, which comprises a plurality of conical jaw segments 38 and coil springs 40. Each jaw segment 38 has a pair of smooth radial sides 42, 44, wherein each of sides 42, 44 is adjacent a side 44, 42, respectively, of a neighbouring segment 38. Each side 42, 44 has a cylindrical recess or pocket 46, essentially midway of side 42, 44, which faces an opposing pocket 46 of adjacent opposing side 44, 42, respectively.

Coil springs 40 are aligned essentially circumferentially (line C-C′ in FIG. 14) within pocket 46, whereby the biasing action of springs 40 is also essentially circumferential as denoted by the arrows in FIG. 5.

FIGS. 6 and 7 show a jaw assembly 50 in exploded position comprising jaw segments 52 and solid, non-metallic deformable biasing members 54, formed of polyurethane in the embodiment shown.

Each of jaw segments 52 has radial sides 56 and 58 which oppose adjacent jaw segments sides 58, 56, respectively. Each of jaw segments 52 has a pair of radial semi-cylindrical troughs 60, one at each of the outer circumference of sides 56 and 58, when the jaw assembly is in its expanded position, but wherein each pair of opposing troughs define an open-ended cylindrical recess 62 when the jaws assembly is in its contracted position as shown in FIGS. 8, 8A and 8B with member 54 in contracted mode denoted CD.

FIGS. 9 and 9A show the jaws assembly in its expanded position, with non-contracted member 54 denoted EX.

Member 54 as shown in FIGS. 10 and 10A, has a body which, is in essence, a peanut-shaped right-vertical obligate cylinder having opposing vertical sides 64, 66 of greater length than intervening adjacent opposing vertical sides 68, 70 when base surface member 54 is placed horizontally. Each of sides 64 and 66 has at a mid-portion thereof, a vertical recess 72, which constitutes a waist of body 54. Side 70 has a rounded protrusion 74 (FIGS. 8A, 9A) running the vertical length of member 54 receivable within complementary inner recess 76 (FIGS. 8A, 9A) to reduce rotation of member 54 within recess 62.

FIG. 11 shows member 54 in a contracted mode.

FIG. 12 illustrates how members 54 would be aligned around the circumference and within recesses 62 of jaw assembly 50.

FIG. 13 shows the essentially circumferential (line E-E′) disposition of coil spring 40 within trough 60.

FIG. 14 shows the essentially radial disposition (along line R-R′) of member 54 within trough 60. It can be seen that in both examples the biasing action of coil spring 40 and deformable member 54 is essentially circumferential within jaw assembly 16 and 50, respectively.

FIGS. 15, 15A and 15B show views of a polyurethane band 80 having a plurality of equally, circumferentially-spaced integrally-formed deformable members 54A around the inner surface 82 of band 80. This arrangement allows for members 54A to be fitted simultaneously around and within recesses 60 of the fingers of the jaw assembly 16, when the latter is in its expanded mode prior to contraction. Such an integral arrangement assists the retention of members 54A within recesses 60 during fitting.

In the manufacture of the jaws assembly according to the prior art, a jaws material, typically, tool steel, is turned to provide the inner and outer conically shaped member having an integral flange. The cone is sliced into the desired number of segments—typically, 8 or 16 segments. Each of the inner radial faces of the segments are drilled to provide metal spring pockets in the middle of the faces. On a typical 8 segment assembly, this involves the drilling of 16 pockets, which must be accurately aligned to share the coil springs with its neighbours. This is a costly procedure in time and finance.

In the manufacture of the jaws of the jaws assembly according to the invention, the aforesaid turned conically-shaped block is radially drilled at the desired locations on the circumference, dependent on the number of segments desired. This requires only 8 drillings, if 8 segments are desired, i.e. 1 drilled recess per segment. The drilled block is then sliced through each recess to give each segment a pair of semi-cylindrical troughs each of which is fully aligned with its neighbour into which each pair of segments is subsequently retained deformable member 54.

It can be readily understood, that the process and product according to the invention has the aforesaid stated advantages over the prior art.

Although this disclosure has described and illustrated certain preferred embodiments of the invention, it is to be understood that the invention is not restricted to those particular embodiments. Rather, the invention includes all embodiments, which are functional or mechanical equivalence of the specific embodiments and features that have been described and illustrated. 

1. An I/O endforming tool for forming an end of a tube, said tool comprising a cone ring expandable and contractable conical I/O jaw means, a barrel assembly, a plurality of I/O fingers and mandrel means, wherein said I/O jaw means comprises a plurality of conical jaw segments, one segment adjacent two neighbouring segments, each segment having a recess within each of its sides adjacent each neighbouring segment and biasing means retained within each recess to effect a biasing effect between adjacent jaw segments the improvement wherein each recess formed at a portion of the outer circumference of each segment as to define a radial trough when said jaw means is in its expanded position; and said biasing means comprises a solid, non-metallic deformable member retained within a circumferential recess defined by a pair of adjacent said troughs when said jaw means is in it contracted position.
 2. A tool as claimed in claim 1 wherein said trough is a semi-cylinder and said deformable member is adapted to be received by two adjacent said semi-cylindrical troughs.
 3. A tool as claimed in claim 2 wherein said deformable member has a body in the shape of a right-vertical obligate cylinder having a pair of opposite vertical sides of greater length than the length of the pair of vertical adjacent sides.
 4. A tool as claimed in claim 3 wherein at least one of said vertical sides of greater length defines a vertical recess.
 5. A tool as claimed in claim 4 wherein each of said vertical sides of greater length defines a recess, constituting said body having a waist.
 6. A tool as claimed in claim 1 wherein at least one of said troughs of each jaw segments defines an inner radial recess within said trough and said deformable member has a protrusion receivable within said inner radial recess.
 7. A tool as claimed in claim 2 wherein at least one of said troughs of each jaw segments defines an inner radial recess within said trough and said deformable member has a protrusion receivable within said inner radial recess.
 8. A tool as claimed in claim 3 wherein at least one of said troughs of each jaw segments defines an inner radial recess within said trough and said deformable member has a protrusion receivable within said inner radial recess.
 9. A tool as claimed in claim 4 wherein at least one of said troughs of each jaw segments defines an inner radial recess within said trough and said deformable member has a protrusion receivable within said inner radial recess.
 10. A tool as claimed in claim 5 wherein at least one of said troughs of each jaw segments defines an inner radial recess within said trough and said deformable member has a protrusion receivable within said inner radial recess.
 11. A tool as claimed in claim 1 wherein said member is formed of a polyurethane.
 12. A method of manufacturing an expandable and contractable I/O jaw means comprising a plurality of conical jaw segments, wherein each segment is adjacent two neighbouring segments at their radially adjacent sides for use in an I/O endforming tool assembly, said method comprising providing an integrally-formed, open-ended, hollow conical member having a body and a radially upstanding circumferential flange adjacent the end of greater outside diameter of said body the improvement comprising (a) drilling a plurality of radial cylindrical recesses within and symmetrically aligned around said flange; (b) slicing said member through said body and said flange through said recesses to provide said plurality of jaw segments, wherein each segment has a portion defining a radial trough at the outer circumference of said segment at each of said radially adjacent sides; which troughs define a plurality of deformable member-receiving cylindrical recesses within and when said I/O jaw assembly is in the contracted position; (c) inserting said deformable members between and within adjacent troughs prior to said I/O jaws being contracted.
 13. A method as claimed in claim 12 further comprising the step of drilling at least one notch-receiving recess within each of said radial, cylindrical recesses prior to step (b).
 14. An I/O jaw assembly when made by a method as claimed in claim
 12. 15. An I/O jaw assembly when made by a method as claimed in claim
 13. 16. An /O jaw segment when made by and for use in an I/O jaw assembly as claimed in claim
 12. 17. An I/O jaw segment when made by and for use in an I/O jaw assembly as claimed in claim
 13. 18. An I/O endforming tool as claimed in claim 1 comprising a circular band having a pluralilty of said deformable members, integrally formed with said band and equally spaced around and radially from the inner circumferential surface of said band, wherein the band is of a suitable inner diameter as to allow the members to be fitted around the jaw assembly when said jaw assembly is in its expanded assembled mode; and is of a suitable thickness as to not interfere with the contraction and expansion of said jaw assembly in operation. 